OUR
CAPABILITIES
WE USE
TPE (Thermoplastic Elastomer)
Thermoplastic Elastomer compound (TPE) based on SEBS (Styrene-Ethylene-Butadiene-Styrene) and PP (Polypropylene) co-polymers is the primary material we process for our priority products: custom-fit floor and trunk mats/liners.
TPE is an advanced fully recyclable, REACH-compliant, odorless and PVC- and Sulphure- free human-health friendly material that can be in any color and formed with various plastic processing technologies. We work with multiple international and local suppliers for formulas according to our customer’s final product preferences.
NR-SBR
We have been working with classic Rubber (Nitrile- and Styrene-Butadiene Rubber) for more than 30 years and in our joint integrated factory, we produce our Rubber compound in-house with primary ingredients before press forming and vulcanization. This is how we make the most competitive rubber floor mats with minimum odor with no regenerated content inside.
Textile
Textile floor mats was the first product of Apesan. In 2020s, we went back to our roots and started rediscovering the vast diversity of textile materials that can be used for making economic and premium floor mats through partnerships and outsourcing. We use EU-made premium PP, PET and PA materials for our textile floor mats projects starting from 300 gr/m2 up to 900 gr/m2 pile weight and with different backside and sideline options.
PROCESSES
Plastic Processing
We have: a plastic extrusion line with 300 kg/hr capacity for TPE and it is integrated to a very flexible and highly automated direct vacuum forming machinery with 4 consecutive stations rotating 360 degrees and a recycling stream equipped with shredding, mixing, and automatic loading mechanics for a closed-loop, waste-free, fast-changing production for low to high quantity production orders.
Plastic Forming
Besides the integrated direct vacuum forming to our extrusion line, we have: a fully automated roll-fed thermoforming line with 40 cycles capacity per hour and an integrated robotic trimming system; a small plastic injection moulding line for producing PA-CF fixation parts; and a new large plastic injection moulding line for TPE floor and trunk mats at high quantities for OEM and Aftemarket.
Tooling & Assembly
In our in-house mold making department, we are CNC tooling, drilling, cutting and bending Metal and Wooden Mold materials and assembling them via welding and mechanical joints. These molds are both used in our own plastic and rubber production lines and exported to other manufacturers as well.
CAPABILITIES
Rubber Compounding
We make our own NR-SBR rubber compound in our banburry integrated latest-tech lines.
Vulcanization
We use vulcanization press machineries specifically designed for interior floor mats production with the highest serial production efficiency.
Textile Cutting & Sewing
We can manufacture floor mats from textile materials via CNC cutting and semi-automated overlock and narrow weaving sewing by our own 2D custom-fit designs.
DEVELOPMENT
3D Scanning
The journey for our custom-fit products start from the vehicle itself. We use Lidar and more advanced point-based 3D scanning technologies to create a digital twin of vehicle floor topographies with complete 3D details with down to +-0.05mm accuracy.
CAD & CAM
Our engineering capabilities include 2D and 3D Computer-Assisted Design for reverse engineering, product modeling, and mold mechanical design via licensed cloud-based Solidworks 3DExperience software and Computer-Assisted Manufacturing programming via licensed Hypermill software.
Prototyping
For faster and more accurate Product Development process, we take advantage of prototyping before finalizing the molds for serial production. For prototyping purposes, we use 3D printing technology as well when it is convenient.
Visualization
For the final part customer approvals, we visualize our products by rendering tools and allow customers to give us feedback for revisions before finalizing the process for serial production.
FACTORS
Control
For every process and line, we implement Quality Control (QC) workflows including visual inspects, measurements, benchmarking, and fitment testing via printed and digital forms and reports.
Measurement
For thermoplastic materials’ quality tests, our simple in-house laboratory equipments include devices for Density, Shore Hardness, Melt Flow Index, Tensile Strength, Digital Calipers and so on.